Folded carton processing machine



March 31, 1959 c. A. ZUREK 2,879,701

FOLDED CARTON PROCESSING MACHINE Filed Dec. 6. 1956 3 Sheets-Sheet 1 3 1 INVENTOR.

CHESTER, A. ZUREK Fig.1 I

March 31, 1959 I c. A. ZUREK 2,879,701

K FOLDED CARTON PROCESSING MACHINE Filed Dec. 6, 1956 I v 3 Sheets-Sheet 2 INVENTOR.

CHESTER A; ZU REK March 31, 1959 c. A. ZUREK 2,879,701

FOLDED CARTON PROCESSING MACHINE FiledDec. 6, 1956: 5 Sheets-Sheet 5 CHESTER A. ZUREK IN VENT0R.

"QM/W Unitd s, Pa ent 2,879,701 FOLDED CARTON PROCESSING MACHINE" Chester A. Zurek, Utica, NY. Application December 6, 1956, Serial N6. 626,733 4 Claims. or. 93-53 This invention relates to carton processing mechanisms and more particularly to a mechanism for removing folded boxes, cartons, and the like, one at a time,'from a stack thereof and opening and feeding them to another station for further operations.

Heretofore various mechanisms have been proposed for :removing and opening folded boxes or cartons from 8. These have generally included the socalled suction type wherein a vacuum or air pressure is mused to withdraw the bottom box from the stack for' opening in a second operation, and the so-called mechansupply thereof.

iical pusher type inwhich a single box is pushed'out from 1 the chopper stack by a small plate or step of the right 2 thickness on a pusher arm. While certain of these marchines have been successful for some operations a gen- 'erally high rate of rejects has been encountered due to M8 I v c 2,879,701

Patented Mar. .31, 1959 Figure 3 is a partial front elevation of the hopper mechanism for feeding a supply of blanks to the machine of Figure 1;

Figure 4 is a top plan view of the hopperwah a box -rugated cartons and the like.

tithe variations in the box, of material dimensions, storage 7 wconditi'ons and the like. variations in surface finishes, inks, and the like and in the (degree of scoring for the folding line cause damage and irejects. Wastage of ten to twenty percent is not uncommon for some of the more diificult types of operations. According to my invention all types of boxes and variations in finishes, quality of paper, depth of scoring, and the like can be handled with equal ease and the folded boxes removed and opened positively anduniformly with improved speed and less waste than heretofore possible.

It is an object of the present invention to provide a folded carton opening and feeding mechanism of improved reliability in operation. It is another object' of the present invention to provide a carton'openingand feeding mechanism that will automatically handle wide variations in composition of the material, surface finish, depth of score line, and the like without waste. It is another object of the present invention to provide a carton contacting mechanism that does not depend upon the thickness of the carton nor external air pressure or vac- 'uum.

box blanks themselves. It is a further object of the present invention to provide a box opening and feeding :mechanism that removes the foldedbox from a supply "thereof and opens it to the completely open position in :a single operation and at a single location. It is'another object of the present invention to provide a positivemeans 'for removing and opening a folded box from a supply "to the present invention;

Figure 2 is an end elevation of the machine of Figure 1;

It has even been'found that 44 and 46. These allow adjustment through screws 48 to adjust for the particular size of folded box placed in- It is another object of the present invention to provide a carton opening and feeding mechanism that will be essentially independent of any bendor'sag in the.

- of the frame 22 to a distance equal to a box width or Referring now to Figures 1 and 2 the box opening and I feeding mechanism 20 comprises generally a frame 22 of angle iron or other suitable material having four or more uprights and a pair of side rails along each side. Mounted on top of frame 22 adjacent one end thereof is a hopper 24 which is adapted to receive therein a supply of folded boxes 26 for opening and processing. The hopper 24 is spaced from the operating bed of the frame 22 approximately the full opened height of a carton 26.

Mounted in the bed of frame 22 is a conveyor chain 28 which carries thereon a plurality of angle pushers 30.

The angle pushers 30 are spaced along the conveyor chain 28 to carry the opened cartons to another station for further operations such as filling of the box and clos-.

ing of the end flaps. The chains 28 are mounted about sprockets 32 at each end of the frame 22 and are spaced apart a distance somewhat less than the length of the folded box to be opened. The sprockets 32 at one end of Figure 1' are driven by'a motor (not shown) as will be described herein. A pair of finger earns 34 and a kicker arm 36 are mounted at the rear end of the machine (right end of Figure 1) and are adapted to aid in the removal of a folded box from the hopper 24. A further box opening mechanism is provided in bayonet 38 which, as may be seen in Figure 2, is mounted on theside of the machine 7 and driven from barrel cam 40 mounted in the lower portion of frame 22..

Returning now to hopper 24 (Figures 1 and 2) it is adjustably mounted on a pair-of columns 42 by brackets the hopper. The hopper generally comprises four angular. frame posts 50 joined together at the top and adjacent the bottom by side plates 52 to form a generally rectangular I hopper or bin for receiving therein the cartons to be opened. As may be seen, each of the plates 52 has adjustable mounting slots 54 therein for varying the respective I be seen in Figure 4 wherein the fingers 57 of the angle plates 56 extend inwardly to engage the bottom edge of the carton 26 shown in dotted lines therein. Adjacent the front of the hopper are the guide rails 58 which extend from inside the hopper outwardly along the bed two to assist in the opening and feeding operation.

In the hopper these two rails 58 engage the longer flap of the folded box 26 so that in effect the box is suspended at four separate points (i.e. two along the rear at fingers 57 and two adjacent the front corners on theflon'ger flap 3 a by the'ra'il s"58)'. The rails 58 stop somewhat short of the width-of the longer flap of the boxblanktsee Figure 5) and the bayonet 38 is positioned at the end thereof.

In the fully withdrawn position bayonet 38 normally just engages the longer flap of the bottom folded box in a manner similar to the rail 58' (see Figure 3). This ensures proper insertion as will be described herein. An

adjustable stop plate 60 is provided a short way up the front face of the hopper 24 to relieve the pressure: of the stack of boxes on thefront portion of the bottom box, which relieves any tendency toward excessive sagging' Mounted forwardly of the hopper 24 on the rails 58 is an adjustable friction bar assembly 62 which acts with.

the rails 58 to holdthe folded and open boxes from too: variousoperations maybe properly accomplished rela tive to eachother; The friction assembly comprises gen- I erally a frame member 64 which has slidably mounted therein a floating friction shoe 66 which carries therein rapid forward movement through the mechanism so that a roller 68 which can be varied in size to give a variation in frictional drag on the box.

Referring now to Figures 1 and 2 the pusher arm 36 comprises generally a rod 70 pivotally mounted at 72 on a rotating cam 74 and having the other end slidably mounted within sleeve 76 which is pivotally mounted] about shaft 78. Cam 74 is driven from shaft 78 through chain 80 and the sprockets 82 and 84 respectively.

Sprocket 84 and cam 74 are mounted on a shaft 86 car ried on a bracket 88 which is adjustably fixed on frame 22to properly position the kicker arm relative to the bottom folded box. The arm 36 carries on its upper end thereof a box or carton contacting pad 90 which is ge'nerally'gum rubber to provide good frictional yet resilient contact with the under surface of the bottom folded box 26. As'may be seen in Figure 5 this pad 90 advantageou'sly comprises an outer rubber sleeve 92 fric-' tionally mounted about the plate94 fixed to arm. This:

ensures along life contact since, as one spot becomes: worn, the sleeve 92 may be rotated slightly about the 0 plate 94 to expose a fresh surface which gives the desired frictional contact.

The finger cams 34 are mounted on stub shafts 96 in suitable bearings on the frame 22. Shafts 96 are driven by chains 98 from shafts 78 in a two-to-one speed ratio such that the finger cams 34 rotate twice as fast as shaft 78 for a purpose which will be described herein. As may perhaps be seen best in Figure 6 the finger cams 34 comprise generally a curved sectorof a circle which give an arc of'contact with the folded boxes.

.The bayoneLme'chanism 38 comprises generally the bayonet arm 100, the vertical driving arm 102 which is pivotally mounted on the frame at 104 and which is normally urged inwardly into the folded carton by a spring. 106 in Figure 2. The motion of bayonet assembly 38:

is controlled by barrel cam which is fixed on a shaft 108, mounted in frame 22.- A suitable cam follower as sembly 11 0 is slidably mounted in collar 112 which is fixed to the frame 22. Cam follower 110 is pivotally mounted at the other end on arm 102 and with spring 106 causes arm 100 to follow the contour of barrel cam 40 as it rotates. In the position shown in Figure 2 the bayonet' arm is in the fully inserted position and as the cam 40 rotates the arm 100 is withdrawn to the n01- mal portion of rest such that the tip of the bayonet 100 just engages the longer flap of the bottom folded box.'

As may be seen in Figure 2 the bayonet arm 100 is pivotally joined to arm 102 at one end and at the otherend has a tapered or pointed face. This is positioned so that the upper surface just engages the extended flap of the bottom box. As it is forced inwardly into the box the tapered slower surfaces guides the entry of the bayonet arni 100 into the box to positively open it at least part way. Shaft 108 is driven from shaft 78 by the chain 114 and associated sprocket wheels.

The entire mechanism is driven by a motor (not shownl V connected through suitable chains to the shaft 78. In

actual operation the gear ratios between the variousdrives are chosen such that the angle pushers 30 will clear one box from under the hopper 24 in one cycle of operation, the pusher arm 36 will make one cycle of its operation which is essentially a rotary motion, the finger cams 34 will make two complete revolutions, and the bayonet arm 100 will makeone complete cycle of operationin and out.

e 7 new cycle.

. ving thei l lpward rotation portion of their cycle.

Figure: 6B shows the next step in the cycle which is the movement of the-bottom box off the fingers 57 by the pusher arm 36 and the riding piggy-back fashion of the front. edge on the preceding opened box. As may be clearly seen in Figure 5 the piggy-back feature provides a nisin according to the present invention.

resilient yet' accurate gate that permits only the desired bottom folded box to escape past the adjustable end plates 53 of Figures 3. This very important feature gives complete support to the front edge of each box -all the'way acrossits entire width and prevents sagging of the boxwhich might interfere with the proper operation of'the mechanism and which in prior devices has proved; a series obstacle. 7 I

Thebox' being removed rides piggy-back on the preceding" opened box until just before the stage shown in Figure 6C. Atthis point the pusher arm 36 has moved out of contact with the rear of the folded box allowing it. to 'drop into the'jpartially opened position shown with the,"front"edge being still held by the preceding box "and with the longer extending side flaps being engaged by the rails 58 so that the weight of the box tends to open itto'the'position shown in Figure 6C. At this point the bayonet arm is moving inwardly (out of the paper in Figure 6) to positively open the folded box.

-"This] is shown in more vivid fashion in 61) at which point" the finger cams 34 are just about to engage the trailing edge of the box to be opened. By this time the upper longer extending flaps of the box are securely engaged' between the rails 58 and the friction assembly 62 p Ed -and; therear edge of the box is engaged by the cam fingers 34." This allows withdrawal of the bayonet arm 100 to be started. ,Also' as may be seen in 6D the angle pushers 30 are approaching engagement with the rear of the box.

In the position shown in Figure 6E'the angle pushers 30 are about'to engage the rear edge of the box to hold it open against the'retarding action of rail 58 and friction 'rnechanisrn 62' so that the bayonet 100 may be com-' pletely withdrawn therefrom. Also finger cams 34 have just about left the] edge of the box. Figure 6F shows 'the jangle' pushers30 having picked up the box and the pusher 'arm 36 just starting to engage the next bottom foldedbox to start it on its journey through the opening process andfeeding channel.

From the foregoingit may be seen that a new and unique method and machine have been provided for removing folded boxes from a hopper and opening them for further operation. A firm four-point support is maintained in'the' hopper and a full width piggy-back support and gating feature is provided to prevent bending and bo ing during'the removal portion of the cycle and to assist in the initial opening of the box. Positive opening of the box itself, a positive maintaining of it in the open positionat alltimes and a positive conveying forward in the fully opened position complete the novel mecha- The novel gating feature of the piggy-back'operation ensures that only one folded box at a time will be removed and this;

removal does not depend upon the type of paper or ink or surface finish of the boxes in the hoppernor does it vary with usage since the build-up of wax or ink or what have you on the pusher arm does not affect the depth of the gate or the discharge of the folded boxes therethrough. Also it should be noted that the carton in the present embodiment is completely opened before it has left-its station underneath the hopper. Thus a more compact machine is obtained permitting economy of space and more-operations in a given area.

While there is given above a certain specific example of this invention and its application in practical use, it should be understood that this is not intended to be exhaustive I or to be limiting of the invention. On the contrary, this illustration and explanation herein are given in order to acquaint others skilled in the art with this invention and the principles thereof and a suitable manner of its application in practical use, so that others skilled in the art may be enabled to modify the invention and adapt and apply it in numerous forms each as may be best suited to the requirement of a particular use.

I claim:

1. A folded box processing machine comprising a frame, a work supporting and transporting bed, a box hopper mounted above said bed adjacent one end thereof, means in said hopper for supporting folded boxes therein at a plurality of spaced points adjacent the bottom edge thereof, a pusher arm for periodically engaging the under side of the bottom folded box, gate means mounted on said hopper and spaced from said bed approximately the height of a fully opened box to prevent more than one folded box at a time being removed from said hopper, bayonet means for positively opening the bottom box at least partially, conveyor means including a plurality of angle arms mounted thereon for picking up the partially opened box, opening it fully and moving it along said bed, and friction means for engaging said boxes to control forward movement thereof and assist in maintaining them in open position.

2. A folded carton processing machine of the type adapted to remove folded cartons one at a time from a stack and open them for filling and further operation comprising a frame having an operating path therein; conveyor means extending along the operating path thereof; a hopper for holding folded cartons, mounted above said conveyor means a distance greater than the height of an opened carton; a pair of guide rails engaging opposite end flaps adjacent the fronts thereof; a pair of fingers mounted on the back of said hopper and extending inwardly to engage the bottom of said folded cartons; a

pusher arm mounted rearwardly of said hopper and carrying thereon a friction pad to engage the under surface of the bottom carton; a bayonet mounted for movement transversely of said path and extending just under one of said end flaps and being adapted to enter into said folded carton; a plurality of cam fingers mounted for rotary motion adjacent the rear of said hopper to assist in opening the cartons, a plurality of angle pushers mounted on said conveyor means to engage the opened cartons and transport them in fully opened position, friction meanscontrolling the forward movement of said cartons and drive means for operating said bayonet pusher arm, and angle pushers one cycle per folded carton.

3. A processing machine for folded cartons of the type having at least one flap on each end longer than the other flaps thereon adapted to remove said cartons one at a time from a stack thereof and open them for further operations comprising a frame member having therealong a generally horizontal operating path; a chain conveyor mechanism disposed along said operating path; a plurality of angle pushers fixed to said conveyor chain at spaced intervals therealong, said spacing of said angle pushers being sufficient to permit one complete cycle of operation Of the apparatus during the time it takes consecutive pushers to pass a given point; a hopper for receiving therein a stack of folded cartons mounted on said frame above said operating path adjacent one end thereof; a plurality of supporting fingers for maintaining said cartons in said hopper said members being spaced along the side and rear edges of said hopper; a discharge gate on the front edge of said hopper said gate being spaced from said operating path a distance equal to the height of an open carton plus the thickness of a folded carton; an elongated pusher arm mounted for free rotary motion of one end thereof; said free end having mounted thereon a friction pad adapted to engage the bottom surface of the bottom folded carton in said hopper, said pusher arm being mounted so that the free end thereof periodically.

contacts the under surface of the bottom carton adjacent the rear edge thereof and lifts it off and forward of the rear support fingers; a bayonet having the end thereof tapered on the underside thereof to a point at the end thereof, the upper edge of said tapered end supporting one of the flaps on the end of said folded carton; spring means urging said bayonet into said cartons, a barrel cam member operatively connected to said bayonet to remove it from Within said cartons; a pair of cam fingers mounted below the rear edge of said hopper so as to engage the rear edge of a carton and to partially open said carton after removal from said hopper; friction means for engaging the upper front edges of the folded carton as it leaves said hopper to restrain movement thereof; said angle pushers engaging the lower rear edge of said folded carton to fully open said box in cooperation with said friction means; and drive means connected to'said apparatus for rotating said bayonet and pusher arm one revolution per carton removed from said hopper and to rotate said cam fingers two cycles per carton removed.

4. A folded carton processing machine of the type adapted to remove folded cartons one at a time from a stack thereof, and open them for further operations such as filling comprising a frame forming an extended operating path, a hopper for holding a stack of folded cartons mounted above one end of said operating path having at least three carton supports adjacent the bottom thereof, pusher means for moving the bottom folded carton off at least one of said carton supports, cam and lever means for opening said removed bottom carton before it is entirely removed from underneath said hopper, a discharge gate mounted on the front of said hopper so as to form a slot equal to the thickness of one folded carton between the preceding opened carton and said gate whereby only the bottom carton may be removed from said hopper on each cycle and conveyor means for transporting said opened cartons along said path.

5. A folded carton processing machine of the type adapted to remove folded cartons one at a time from a stack thereof, and open them for further operations such as filling comprising a frame forming an extended operating path, a hopper for holding a stack of folded cartons mounted above one end of said operating path having at least three carton supports adjacent the bottom thereof,,

pusher means for moving the bottom carton off at least: one of said carton supports, cam and lever means foropening said removed bottom carton before it is entirelyremoved from underneath said hopper, discharge gatemeans mounted at the front of said hopper forming with, the preceding opened carton means for supporting the:

folded carton to be discharged throughout its entire Widtln for sliding said bottom box partially out of said hopper, gate means mounted on said hopper so as to form a slot equal to the thickness of one folded carton between the. preceding opened carton and said gate, bayonet means for positively opening said boxes at least partially, cam means:

fornholding said box partially opened during withdrawal of: said bayonet, conveyor means for fully opening said box and transporting it along said path and friction controlling means mounted adjacent the discharge. side of said hopper to engage said boxes as they are pushed from said hopper and to control the forward movement thereof for the. opening operations.

7. A folded box processing machine adapted to remove foldediboxes one at a time from a hopper, said boxes being of the type having the so-called economy flaps, comprising in combination, a main frame portion having an operating path extending therealong, conveyor means mounted in said path, a hopper for holding a supply of folded boxes mounted above one end of said. path, a plurality of support members extending inwardly into said hopper supporting said folded boxes at the two longer flaps and rear edge thereof, friction pusher means for moving the bottom boxes off said rear edge supports, guide means for frictionally engaging said longer flaps, bayonet and cam means for positively opening said folded boxes, and a plurality of right angle pushers mounted on saidconveyor so as to sequentially engage the opened boxes removed from said hopper whereby opened boxes are 'moved in the fully open position under the control of said guide means and angle pushers from under said hopper along said path.

8. A processing machine adapted to remove folded cartons, of the type havingat least one flap on each end longer than the other flaps thereon, one at a time, from a stack thereof and open them for further operations comprising a frame member having therealong a generally horizontal operating path; a conveyor mechanism disposed along said operating path; a plurality of angle pushers fixed to said conveyor mechanism at spaced intervals therealong, said spacing of said angle pushers being suflicient to permit one complete cycle of operation of the apparatus during the time it takes consecutive pushers to pass a given point; a hopper for receiving therein a stack of folded cartons mounted on said frame above said operating path adjacent one end thereof; a plurality ofsupporting fingers for maintaining said cartons in said hopper; a discharge gate on the front end of said hopper said gate being spaced from said operating path a distance equal to the height of an open carton plus the thickness of a folded carton; an elongated pusher arm mounted for free rotary motion of one end thereof; saidpusher arm being mounted so that the free end thereof periodically contacts the under surface of the bottom carton adjacent therear edge thereof and lifts it off certain of said support fingers; a bayonet member having the upper edge thereof supporting One of the flaps on the end of said folded carton; means urging said bayonet transversely of said operating path into said cartons; cam means operatively connected to said bayonet member to periodically remove it from within said cartons; a pair of cam fingers rotatably mounted below the rear edge of said hoppers so as to engage the rear edge of a partially opened carton, friction means, for engaging the upper front edges of thefolded carton as it leaves said hopper to control movement thereof; and driving means operatively connected to said apparatus for actuating said bayonet and pusher arm one cycle. percarton removed from said hopper andv to' rotate said cam fingers two cycles percarton removed.

comprising a frame member having therealong an opcrating path; a conveyor-mechanism disposed along saidoperating path; a plurality of pusher members fixed to said conveyor mechanism .at spaced intervals therealong,

said spacing of said angle pushers being sufficient to per mit one complete cycle ofoperation of the apparatus duringthe time it takes consecutive pushers to pass a given, point; a hopper for receiving therein a stack of folded cartons mounted on said frame above said operating path adjacent one end thereof; a plurality of supporting fingers for maintaining said cartons. in said hopper; a discharge gatespaced from said operating path a distance equal to thehelght of an open carton plus the thickness of a folded carton; an elongated pusher, arm mounted so that one end thereof periodically contacts the under surface of the bottom carton adjacent the rear edge thereof; a

bayonet member having one edge thereof supporting one of the flaps-on the end of said folded carton; meansfor selectively moving said bayonet transversely of said operating path into and out of said cartons; a plurality of cam fingers mounted adjacent the rear edge of said hop: pers so as to engage the rear edge of a partially opened carton, friction means for engaging the front portion of the folded carton as it leaves said hopper ,to control movement thereof; and driving means operatively connected to said apparatus for actuating said bayonet and pusher arm one cycle per carton removed from said hopper and to rotate said cam fingers two cycles per carton removed.

10. A processing machine adapted to remove folded cartons of the type having at least one flap on each end longer than the other flaps thereon, one at a time, from. a stack thereof and open them for further operations comprising a frame member, a conveyor mechanism; a

plurality of pusher members fixed to said conveyor mechanism at spaced intervals therealong; a hopper for re-.

ceiving therein a stack of folded cartons mounted on said frame above said operating path adjacent one end thereof; a plurality of supporting fingers for maintaining said cartons in said hopper; a discharge gate mounted on said hopper gate, said gate being spaced from said operating path a distance equal to the height of an open carton plus the thickness of a folded carton; an elongated pusher 7 arm mounted so that one. end thereof periodically contacts the under surface of the bottom carton adjacent the rear edge thereof, a bayonet member; means for selectively moving said bayonet transversely of said operating path into and out of said cartons, a plurality of camfingersmounted so as to engage the rear edge of a partially opened carton, friction means for engaging the folded carton as it leaves said hopper to control movement thereof; and driving means operatively connected to said apparatus for actuating said bayonet, pusher arm, and cam fingers.

References Cited in the file of this'patent UNITED STATES PATENTS 2,147,994 Schwinger Feb. 21, 1939 

